Batch Torrefaction Reactor Layout for Fibrous Biomass Processing

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Solution Overview

Problem

Existing torrefaction processes for biomass are complex and require large scales, making them economically unviable for processing fibrous biomass like bagasse, and fibrous biomass tends to bridge and not flow through large openings, necessitating energy-intensive milling.

Innovation Solution

A configuration of multiple batch reactors connected to air drying, torrefaction, and cooling gas loops, allowing for batch processing of fibrous biomass without flowing, using the same reactor for drying, torrefaction, and cooling, and utilizing a rotating valve for efficient gas loop connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If continuous torrefaction processes are used, then productivity is improved, but device complexity and scale requirements increase making them economically unviable for fibrous biomass

Engineering Contradiction:

Improvetorrefiction throughputVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The continuous process is segmented into multiple batch reactors operating in sequence, where each reactor handles a specific stage (drying, torrefaction, cooling) to maintain productivity while reducing overall system complexity and scale requirements

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple batch reactors are operated in a cyclic sequence to achieve continuous processing output, where while one reactor is drying, another is torrefying, and a third is cooling, maintaining continuous productivity without requiring a single large continuous system

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If large scale continuous processes are used, then productivity is improved, but transportation costs increase due to need for large biomass volumes from large areas

Engineering Contradiction:

Improvetorrefiction throughputVSAvoidtransportation cost

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The process is divided into smaller modular batch reactors that can be deployed closer to biomass sources, reducing the volume of biomass that needs to be transported over long distances while maintaining overall productivity through parallel operation

Inventive Principle:

Principle #1Segmentation

3Productivity

If fibrous biomass is processed in continuous processes, then productivity is improved, but bridging issues occur preventing proper flow through the reactor

Engineering Contradiction:

Improvetorrefiction throughputVSAvoidbiomass flowability

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

Batch reactors operate with periodic cycles of drying, torrefaction, and cooling, allowing fibrous biomass to be properly handled at each stage without the continuous flow requirements that cause bridging problems, while maintaining productivity through sequential operation

Inventive Principle:

Principle #19Periodic action

4Ease of operation

If fibrous biomass is pre-treated with milling and shaping, then ease of operation is improved, but energy consumption increases significantly

Engineering Contradiction:

Improvebiomass processabilityVSAvoidpre-treatment energy consumption

Core Design Contradiction:

Ease of operationVSUse of energy by stationary object

Solution Approach 1:

The energy-intensive milling and shaping pre-treatment steps are extracted and eliminated from the process, with the batch reactor system directly handling fibrous biomass through sequential drying, torrefaction, and cooling stages that require minimal prior preparation

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables efficient, energy-efficient processing of fibrous biomass in smaller scales, reducing transportation costs and eliminating the need for energy-intensive milling, while maintaining uniform torrefaction quality.

Implementation Method 1

a gas permeable biomass holding structure positioned within the housing defining a biomass holding space as present between the gas inlet and the gas outlet

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

Torrefaction is a well-known process wherein biomass is heated to an elevated temperature in the absence of any substantial amount of oxygen at conditions wherein the hemicelluloses as present in the biomass decomposes

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 3

Torrefaction thereby increases the heating value per mass biomass and also removes a substantial amount of water, especially so-called bound-water, from the biomass

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12606761B2Torrefaction reactor and process

Publication Date: 2026.04.21 TORRGREEN TECH BV

AI summary

The invention is directed to a configuration comprising of more than one torrefaction batch reactors. A torrefaction batch reactor of the configuration comprises of a closed housing (2) having a gas inlet (4), a gas outlet (5) and a gas permeable biomass holding structure (6) positioned within the housing (2) defining a biomass holding space (7). The gas inlet (4) and the gas outlet (5) of the torrefaction batch reactor are alternatively fluidly connected to the following gas loops, (i) an air drying gas loop (20), (ii) a torrefaction gas loop (25), and (iii) a cooling gas loop (26). One or more batch reactors of the configuration are fluidly connected to the air drying gas loop (20) and one or more other batch reactors are fluidly connected to the torrefaction gas loop (25).